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Personal injury or death can result from improperly checking for a leak.Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning any work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.
Do not service the high-pressure fuel system before releasing the remaining high-pressure fuel from the system. Refer to Testing and Adjusting, "Fuel Rail Pressure - Release".All the parts of the fuel system must be clean. Contaminants will cause rapid wear. Contaminants will also cause shortened component life.The high-pressure fuel system uses joints that consist of a spherical ball and a conical socket. These joints provide improved sealing at high fuel pressures. Protective end caps must be used when the high-pressure fuel system is serviced. Do not reuse the protective end caps.Each joint of the high-pressure fuel system must be cleaned before the system is disassembled. Each joint of the high-pressure fuel system must be cleaned before a component is installed, including new parts.A problem with the components that supply fuel to the engine can cause low fuel pressure. Low fuel pressure can decrease engine performance.
Check the fuel level in the fuel tank. Look at the cap for the fuel tank. Make sure that the vent is not filled with debris.
Check the fuel lines for fuel leakage. Be sure that none of the fuel lines have a restriction or a faulty bend.
Install new main fuel filters. Make sure the primary fuel filter/water separator is clean. Replace the primary fuel filter/water separator, if necessary.
Check the outlet pressure of the fuel transfer pump. Ensure that you are building a minimum of 250 kPa (36 psi) (gauge) of fuel pressure, which is the minimum pressure required to open the inlet check valves on the high-pressure pump. If the fuel from the tank is on, then remove the low-pressure transfer pump and verify that the drive shaft is not broken. If the transfer pump is okay, then replace the low-pressure regulator.
Purge the air from the fuel system. Refer to the OEM information on how to prime the fuel system.
Check for fuel leaks on the high-pressure system. Verify that no leaks are present by inspecting the ports on the double wall fuel lines.
If leaks are found in the high-pressure fuel system following a repair, remove the accumulator plugs at the repair site. Perform a "Fuel System Functional Test" in Cat® Electronic Technician (ET). Reinstall the accumulator plugs after completion of the test.